SICK VICOTEC410 Operating instructions

OPERATING INSTRUCTIONS

Installation

Operation

Maintenance

Front page

VICOTEC410

CO and Visibility Measuring Device

2 VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG

Document Information

Described Product:

Product name: VICOTEC410

Variants:

Document ID

Title: Operating Instructions VICOTEC410

Part No.: 8008981

Version: 2.0

Release: 2012-09

Manufacturer

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

Phone: +49 7641 469-0

Fax: +49 7641 469-1149

E-mail: info.pa@sick.de

Original Documents

The English edition 8008981 of this document is an original docu-

ment of SICK AG.

SICK AG assumes no liability for the correctness of an unauthor-

ized translation.

Please contact the manufacturer or your local representative in

case of doubt.

Legal information

Subject to change without notice.

Glossary

Skilled persons: Persons who, based on their technical training

and knowledge as well as knowledge of the relevant regulations,

can assess the tasks given and recognize the dangers involved.

Competent person: Persons who, based on their technical training

on, and knowledge concerning the specific device, as well as

knowledge of the relevant regulations, can assess the tasks given

and recognize the dangers involved.

Instructed person: Persons properly instructed on the tasks

assigned, possible risks and necessary protective measures.

VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG 3

Warning Symbols Warning levels / Signal words

DANGER

Risk or hazardous situation which will result in severe personal

injury or death.

WARNING

Risk or hazardous situation which could result in severe personal

injury or death.

CAUTION

Hazard or unsafe practice which could result in personal injury or

property damage.

NOTICE

Hazard which could result in property damage.

Information Symbols

Hazard (general)

Hazard by voltage

Important technical information for this product

Important information on electric or electronic func-

tions

Nice to know

Supplementary information

Link to information at another place

Contents

1 VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG

1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Main safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1.1 A

uthorized personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1.3 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1.4 Correct handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1.5 Avoiding consequential damage arising from device malfunctions . . . . . . . . . . . . . . 6

1.1.6 Environmentally acceptable behavior and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2.1 Purpose of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2.2 Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.3 Responsibility of user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.4 Additional documentation/information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Product identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Features of the VICOTEC410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2.1 Method of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.3 Device variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.3.1 Standard components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.3.2 Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4 Functional principle/measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.5 Special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.5.1 Special device version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.6 Device components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.6.1 VICOTEC410 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.6.2 Evaluation unit RCU410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.7 RCU interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.7.1 RCU interfaces– standard version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.7.2 RCU410 interfaces – Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.8 Fog correction via the RCU410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.9 Screening out fog on measuring points close to the portals . . . . . . . . . . . . . . . . . . . . . 13

2.10 Fog correction via control technology before the portals . . . . . . . . . . . . . . . . . . . . . . . . 14

3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1 Project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.2.1 Protection devices/protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3 Material required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4 Preparing the installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4.1 Overview of installation work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.5 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.6.1 Fitting the mounting brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.6.2 Installing the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Contents

VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG 2

3.7 Installing the terminal boxes and connection unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.7.1 Fitting the terminal boxes (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.7.2 Fitting the connection unit to distant evaluation unit . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.8 Installing the evaluation unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.9 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.9.1 Connecting VICOTEC410 cabling variants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.9.2 Connecting the VICOTEC410 sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.10 Evaluation unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.10.1 Evaluation unit as standard version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.10.2 Evaluation unit connections - PROFIBUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4Start-up / Switching on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.1 Necessary technical knowledge for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.2 Safety information on start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.3 Preparing for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.4 Operating elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.4.1 Function buttons and menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.4.2 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.5 Commencing start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.5.1 1st step: Power supply ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.5.2 2nd step: Setting VICOTEC410 parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.5.3 Fog correction with additional VICOTEC411 measuring point close to portal . . . . 45

4.5.4 Connecting the PROFIBUS during start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.5.5 Call up Parameter mode in the Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.5.6 Zero adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.6 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.1 Authorized persons/access protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.1.1 Recognizing an unsafe operating state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.2 Standard procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.2.1 Checking malfunction displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.3 Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.4 Status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

6.1 Technical knowledge necessary for shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.2 Safety information on shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.3 Shutdown preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.4 Switch-off procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.5 Switching the device off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.6 Protective measures for the shutdown device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.6.1 Measures for short-term shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.6.2 Measures for long-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.7 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Contents

3 VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7.1 VICOTEC410 maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.1.1 Maintenance planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.2.1 Cleaning the sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.3 Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

7.3.1 Recommended spare parts for 2 years operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8 Clearing Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

8.1 VICOTEC410 malfunction handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

8.1.1 Troubleshooting and clearing malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

8.1.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

8.1.3 Further tips on troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.1.4 Sensor values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9.1 Compliances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

9.1.1 Electrical protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

9.1.2 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

9.1.3 Laws, standards, guidelines complied with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

9.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

9.2.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

9.2.2 Dimensions, VICOTEC410 sensor and evaluation unit . . . . . . . . . . . . . . . . . . . . . . . . 78

9.2.3 Dimensions, connection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

10 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

10.1 Main safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

10.1.1 Authorized personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

10.1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

10.1.3 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

10.1.4 Correct handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

10.1.5 Avoiding consequential damage arising from device malfunctions . . . . . . . . . . . . . 82

10.1.6 Environmentally acceptable behavior and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . 82

10.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

10.2.1 Purpose of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

10.2.2 Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

10.3 Responsibility of user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

10.4 Additional documentation/information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Important Information

VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG 6

Subject to change without notice

VICOTEC410

1 Important Information

Main safety information

Main operating information

Intended use

Own responsibility

7 VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG

Important Information

Subject to change without notice

1.1 Main safety information

1.1.1 Authorized personnel

Persons responsible for safety must ensure the following:

 All work on device parts is carried out by qualified personnel only. Qualified persons are

those who, based on their training, experience or instruction as well as their knowledge

of relevant standards, regulations, accident prevention rules and plant conditions, are

authorized by those responsible for safety for personnel and the plant to carry out such

work. It is decisive that these persons can recognize and avoid possible hazards in a

timely manner.

 Skilled persons are persons according to DIN VDE 0105 or IEC 364 or directly compara-

ble standards such as DIN 0832.

 These persons have adequate knowledge through training

 These skilled persons have the delivered Operating Instructions as well as the associ-

ated system documentation available during all work, and observe these documents

with regard to avoiding hazards and damage.

Contact the manufacturer before using this measuring device for other purposes where the

device functionality cannot be judged properly within such applications.

1.1.2 Intended use

 The VICOTEC410 measuring system and its system components are only to be used for

measuring visibility and/or CO concentrations in road tunnels.

1.1.3 Prerequisite

All planning, assembly, installation, start-up, maintenance and repair work must be carried

out by adequately instructed personnel only and checked by the responsible skilled per-

sons.

1.1.4 Correct handling

 Use the system in accordance with the technical data and specifications regarding per-

missible usage, assembly, connection, ambient, and operating conditions (refer to the

order documents, device user information (type plates etc.), as well as the documenta-

tion supplied with the system).

 Persons carrying out the work must be aware of, and observe general assembly and

safety regulations,

 Act according to local, system-specific conditions and risks arising from technical oper-

ating and regulations, in particular local road safety regulations.

 Ensure proper use of tools and hoist and transport equipment.

 Provide sufficient protection devices and personal safety equipment and ensure that

these are used by the personnel.

 Secure system components delivered without a degree of protection with effective pro-

tection devices on-site.

 Observe all measures necessary for conservation of value, e.g. during transport and

storage and/or maintenance and inspection.

Important Information

VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG 8

Subject to change without notice

1.1.5 Avoiding consequential damage arising from device malfunctions

In order to avoid malfunctions that can lead to direct or indirect person or property dam-

age, the operator must ensure:

 Personnel responsible for maintenance can be informed at any time and as quickly as

possible.

 Maintenance personnel are trained to be able to respond to malfunctions on the

VICOTEC410 and to react correctly to related operational malfunctions.

 Defective operating resources are switched off immediately in case of doubt.

 That switching off does not lead directly to subsequent malfunctions.

 Switching outputs “Data valid” for CO and VIS are wired correctly and are processed in

the control station without having to close the tunnel.

1.1.6 Environmentally acceptable behavior and disposal

 Observe applicable waste disposal regulations to protect the environment.

 Sensor subassemblies are easy to dismantle and disposed of as waste.

 Sensor outer housing, optics chassis and brackets are made of aluminium and can be

recycled.

1.2 Intended use

1.2.1 Purpose of the device

Operate the VISOTEC410 visibility/CO measuring device as specified by the manufacturer,

i.e. only use the VICOTEC410 measuring system and its system components to measure

visibility and/or CO concentrations in road tunnels.

1.2.2 Installation location

The opto-electronic VICOTEC410 measuring device supports continuous, delay-free mea-

surement of visibility and CO concentrations in road tunnels. The sturdy, compact sensors

are designed as contact-free, direct in-situ measuring devices.

.

NOTICE: Procedure when cleaning the tunnel



Switch the VICOTEC system to operating mode “Maintenance”



Be sure to cover sensor tubes with closure caps



Never touch sensors directly with washing brushes (risk of modifying

optical alignment which can cause a device malfunction)



After cleaning, check the optical interfaces of the sensors for contami-

nation; when necessary, clean the optical interfaces in accordance with

maintenance regulations, see p. 62, §7.2.1.

NOTICE: Suitable disposal!



Do not dispose of electronic components from VISOTEC410 system compo-

nents as household waste. Dispose of these components in a suitable facil-

ity.

9 VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG

Important Information

Subject to change without notice

1.3 Responsibility of user

These Operating Instructions serve understanding the function, and explain assembly,

installation and maintenance work as well as how to operate the VICOTEC410. Other docu-

ments may contain more detailed information but can never replace these Operating

Instructions.

Target groups of this document

 SICK Service technicians or trained customer personnel; qualified technicians/engi-

neers - with excellent device knowledge

 Operators. customer installation personnel, technicians for measurement and control

technology, electric, electronics - with basic device knowledge

Correct use



Only use the device as described in these Operating Instructions (--> page 44). The

manufacturer bears no responsibility for any other use.



Carry out the specified maintenance work.

 Do not remove, add or change any components in or on the device unless such changes

are officially allowed and specified by the manufacturer. Otherwise any warranty by the

manufacturer becomes void.

Special local conditions



Follow all local laws, regulations and company-internal operating directives applicable

at the installation location.

Keeping documents

These Operating Instructions:



Must be available for reference.



Must be passed on to new owners.

1.4 Additional documentation/information.



Check the contents of the CD delivered with the product (PN:2058621).

Read the Operating Instructions before starting the work! Observe all warning

information exactly!

Product Description

VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG 10

Subject to change without notice

VICOTEC410

2 Product Description

Product identification

Functional principle

Characteristics

Variants

11 VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG

Product Description

Subject to change without notice

2.1 Product identification

The type plate is located

 Sender or reflector/receiver unit: On the back of the housing.

 RCU410: On the right outer side of the housing.

2.2 Features of the VICOTEC410



Simultaneous and single visibility and CO concentration measurement



Comfortable operation via a menu-controlled graphic display on the evaluation unit



Automatic adjustment function (AutoAdjust) for simple start-up



Minimum effort for installation, start-up and maintenance.

The option of simultaneous as well as single visibility and CO concentration measurement

opens up flexible application possibilities for the VICOTEC410, such as:

 Monitoring short tunnel sections or underpasses with one measuring point

 Monitoring longer tunnel sections

 Integrating a fog sensor for each tunnel portal (max. 2 fog sensors)

Fig. 1 VICOTEC410 system layout

Product name: VICOTEC410

Product variants:

VICOTEC411 (VIC411), VICOTEC412 (VIC412), VICOTEC414

(VIC414)

Firmware version: Program RCU410 (9054915 Version O362)

Manufacturer:

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

Fog sensor

V

isibility,

CO concentr

ation

Tunnel lenght

Dis

tance*

Fog sensor

VICOTEC410 standard device

Control center (provided by customer)

Ventilation system

Product Description

VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG 12

Subject to change without notice

2.2.1 Method of operation

The VICOTEC410 operates independently.

 The measuring principles used support extensive options for excellent self-monitoring

 When a malfunction occurs, the VICOTEC410 switches automatically to “Malfunction”

mode. The analog outputs are set to the parameter value set for malfunctions, “Live

zero”, or the last valid value.

Operating states are signaled by status signals and entered in a logbook.

Each sensor pair of a measuring point has one or two opto-electronic measuring devices

that deliver, independent of each other, visibility and/or CO concentration measured val-

ues. The CO measuring unit (IR unit) comprises an infrared sender and an infrared receiver.

The visibility measuring unit (VIS unit) is arranged in parallel and comprises a sender/

receiver unit and a triple reflector.

2.3 Device variants

2.3.1 Standard components

 Sensor pair (sensor “left”, “right”)

 Control unit RCU410

 2 mounting brackets

 Extension cable, 12 m, 6 pole; plug and socket C16-1

 Connection cable, 2 m for sensor - control unit connection

Fig. 2 Device versions

Sensor “left” Sensor “right”

Evaluation unit RCU410

Type plate

Table 1

Device variants Measuring task

VICOTEC411 Single visibility measurement

VICOTEC412 Single CO concentration measurement

VICOTEC414 Simultaneous visibility and CO concentration measurement

13 VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG

Product Description

Subject to change without notice

2.3.2 Optional equipment

The VICOTEC410 can also be configured with

 1 terminal box, “sensor left”

 1 terminal box, ”sensor right”

 Connection unit with separate voltage supply (230 V AC); allows locating the RCU410

up to 1000 m away (CAN bus)

 Repeater for RS422

 Additional prefabricated connection cables:

– 1 connection cable, 1 m for sensor - evaluation unit connection

– 1 extension cable, 24 m, 6 pole; plug and socket; C16-1, to connect both sensors

 2 mounting brackets incl. fixing accessories in material 1.4529 or 1.4571

 Plastic separator plate for using the stainless steel consoles

 Surge protection elements

2.4 Functional principle/measuring principle

 Visibility measuring principle: Transmission measurement (NDIR), auto-collimation

method

 CO concentration measuring principle: Negative gas correlation

2.5 Special features

 Sturdy design proven in hundreds of tunnels

 Long optical measuring distance (2 x 10 m) for exact measured value recording and

simple installation, even in curves, as well as easy alignment

 Automatic contamination compensation on visibility and CO measuring channel

 Simple and fast check of all measured variables possible using closed gas cells (CO) or

neutral density glasses (visibility)

 Early alarm for maintenance request (contamination) for optimized maintenance cycle

planning

 Effective dust protection tubes, heated reflector and thermal insulation allow typical

maintenance intervals of 1 year

2.5.1 Special device version

The VIC412 (Individual measurement of CO-concentration) is also available in a 20 m

version. The measuring distance can be adjusted from 19,5 to 20,5 m.

There is no difference to the standard device with regards the optical alignment and opera-

tion of the device.

Device type: VIC412-22S07 material-no. 1054383

The 20 m - measuring distance is only available for the version VIC412 .

Product Description

VICOTEC410 · Operating Instructions · 8008981 V2.0 · © SICK AG 14

Subject to change without notice

2.6 Device components

2.6.1 VICOTEC410 sensors

Fig. 3 Sensor versions

2.6.2

Evaluation unit RCU410

Each measuring device has an evaluation unit (Remote Control Unit), the RCU410. The

RCU410 provides the recorded measured data as analog and digital signals and performs

the following functions:

 Measuring system operation

 Measuring and status signals evaluation and output

 Sensor voltage supply

2.7 RCU interfaces

2.7.1 RCU interfaces– standard version

 3 relays:

– VIS malfunction

–CO malfunction

–Service/Dust/Warning

 2 analog outputs

– VIS: 0 ... 20 mA; Live-Zero: 4 mA

– CO: 0 ... 20 mA; Live-Zero: 4 mA

 1 digital input

– Service switch

The RCU410 also has an RS422 interface (electrically isolated) on which all measured

data are made available with status messages.

Sensor “left”

 VICOTEC 411: VIS reflector

 VICOTEC 412: CO sender

 VICOTEC 414: VIS reflector/CO sender

Sensor “right”

 VICOTEC 411: VIS sensor

 VICOTEC 412: CO receiver

 VICOTEC 414: VIS sensor/CO receiver

Visor

Dust protection tube

Sensor housing Optical visor

Product Description

Subject to change without notice

2.7.2 RCU410 interfaces – Profibus

 1 digital input

– Service switch

 Interfaces

–PROFIBUS interface

– RS422 interface

Fig. 4 RCU410 evaluation unit

2.8 Fog correction via the RCU410

VICOTEC411s are installed just as fog sensors at a maximum distance of 10 m from the

portals. These are connected to the VICOTEC4xx measuring points (tunnel sensors) via an

RS422 bus circuit. An RCU410 declared as Master then corrects the measured values of

the tunnel sensors when fog exists so that no fog is suctioned in. Details on parameter set-

tings, see p. 45, §4.5.2.

2.9 Screening out fog on measuring points close to the portals

Apart from the possibility of detecting fog and taking appropriate measures, SICK also

offers a device that does not record fog as visibility factor (e.g. VISOTEC450). This device is

used preferably at those measuring points closer than 300 m from a portal. This prevents

fog being assessed as visibility factor and initially avoids erroneous switching to suction in

fresh air.

RCU4 10

Evaluation Unit

7

120.3

Measuring

T=150 oC

T=25 ºC

150

7

CO

VIS

ppm

1/km

0

120.3

Measure

Graphic display for meas-

ured value display and

navigation

Cutout in housing cover (to

show operating elements)

Keypad for

operating the

VICOTEC410

LED status indicators

Front panel with operating

elements (behind glass cover)

Product Description

Subject to change without notice

2.10 Fog correction via control technology before the portals

If visibility distance measuring devices (e.g. VISIC620 from SICK) are used before the por-

tals, it is recommended to design ventilation control so that fresh air is only suctioned into

the tunnel when it can be expected that this will improve visibility or when necessary to

maintain other limit values (NO2, CO,..). An improvement in the visibility distance can then

be expected when the visibility in the tunnel (heat transmission coefficient - HTC) is much

worse than the heat transmission coefficient to be expected when suctioning in fog. In this

case, it is important to observe that a larger volume of condensation crystals is inside the

tunnel than outside the tunnel which thickens any fog suctioned into the tunnel. This effect

cannot be calculated beforehand so it is recommended modeling this in the control with an

adjustable variable (referred to here as “Delta heat transmission coefficient”) so that it can

be adapted during the tunnel operation test phase. The following Table provides assistance

for converting visibility distance into a heat transmission coefficient in stages without hav-

ing to use a complex mathematic formula. Detailed consultation can be requested from the

local SICK contact person.

This fog correction method has the advantage that measured values in the tunnel always

reflect the actual visibility. This ensures a warning or closure when visibility is poor.

Table 2 Visibility distance to heat transmission coefficient conversion Table

Visibility distance

As HTC converted visi-

bility distances

Delta HTC (only as an

example here)

HTC expected in the

tunnel

900 m 3.3/km 2/km 5.3/km

800 m 3.75/km 2/km 5.75/km

700 m 4.3/km 2/km 6.3/km

600 m 5/km 2/km 7/km

500 m 6/km 2/km 8/km

450 m 6.7/km 2/km 8.7/km

400 m 7.5/km 2/km 9.5/km

350 m 8.6/km 2/km 10.6/km

300 m 10/km 2/km 12/km

250 m 12/km 2/km 14/km

Product Description

Subject to change without notice

Installation

Subject to change without notice

VICOTEC410

3 Installation

Project planning

Transport

Setup

Installation

Initial start-up

Installation

Subject to change without notice

3.1 Project planning

3.2 Safety information

The following symbols are used in these installation instructions for important safety infor-

mation for the user. The symbols are located exactly where required within the Sections.

Safety information, especially warnings, must be observed and followed.

3.2.1 Protection devices/protective measures

3.3 Material required

Table 3 Materials and Part Nos. for assembly

3.4

Preparing the installation location



Secure the place of work



Provide adequate light, power and a jack lift at the place of work



Provide fixing accessories, suitable drills and tips, circuits, socket wrench set, torque

wrench, marking material, measuring tools, spirit level.

DANGER: Hazards through electrical equipment

VICOTEC410 system components are operating resources for use in industrial

high-voltage systems. These operating resources have parts that are danger-

ous, live and possibly not insulated during installation, start-up and operation.

Unauthorized removal of required covers, incorrect usage or operation or inad-

equate maintenance of system components referred to above can cause

severe health or material damage.

WARNING: Preventive measures for operating safety

If the VICOTEC410 is used as a sensor in combination with a control system,

the operator must ensure that a failure or device malfunction on the

VICOTEC410 cannot cause unallowed damage or hazardous operating states,

or states that can endanger or obstruct traffic.

Material required Part No.

Assembly kit for mounting brackets for VICOTEC32x, 41x, dowels and

screws made of stainless steel 1.4571

2045457

Assembly kit for mounting brackets for VICOTEC32x, 41x, dowels and

screws made of stainless steel 1.4529

2045458

Insertion tool for stainless steel dowel, M12 5601225

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SICK VICOTEC410 Operating instructions

SICK VICOTEC410 Operating instructions

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